Pulp Molded Biodegradable Remove-ably Connectable Lid

ABSTRACT

By creating a slurry of biodegradable material, forming it in a mold under a vacuum, a channel may be created in the lid which can be release-ably connected to a traditional rolled lip coffee cup, among other common liquid holding vessels but be made out of biodegradable material. The resulting lid may be elastic enough such that the lid will give to allow a complementary cup to fit into the channel to create a seal between the cup and the lids. It also will be firm enough to withstand the weight and pressure of the liquid inside the container and from pressure from consumers while using the container. The lid also may be sufficiently heat resistant to withstand desired temperatures and liquid exposure for a time long enough for a consumer to enjoy the contents of the container but also be biodegradable.

BACKGROUND

This Background is intended to provide the basic context of this patentapplication and it is not intended to describe a specific problem to besolved.

Packaging used for containment of liquids can generate large amounts ofwaste. In some cases, packaging used for containing liquids or lids forcapping liquid containers/vessels may be recycled. More recently, it hasbecome common to use bottles and lids made from plastics, such as PET orHDPE, for liquid such as water, juice, carbonated drinks, or milk. Inthis case, it is common for the bottles or lids to be formed fromvirgin, i.e. non-recycled, material to ensure that the liquid containedwithin the bottle is not contaminated as could be the case if thecontainers were formed from recycled material. While the material itselfcould be recycled if separated from other waste, as with glass bottlesthis frequently does not occur due to the need for the waste producer,such as a householder, to separate the containers from other wastematerial. Again, if the container or lids is disposed of in a landfillsite or the like, the bottle or lids is not biodegradable.

It has also been proposed to package and cap liquid in laminatedcardboard containers, for example in containers marketed by Tetra Pak.In this case, the cardboard from which the body of the container isformed may be virgin or recycled material. The cardboard is laminatedwith a waterproof coating. This ensures that the container is able tohold liquid and also acts as a barrier between the liquid and thecardboard, which can prevent contamination of the liquid from thecardboard. This is especially needed where the cardboard is formed fromrecycled material A problem with such packages is that they aredifficult to recycle, and the waterproof coating prevents them fullydecomposing.

Manufacturing a biodegradable release-ably connectable lid has long beena challenge. Forming a channel using biodegradable material which doesnot unacceptably degrade, deform or discolor when in contact with hotliquid such as coffee has been thought to be impossible. By creating aslurry, forming it in a mold under a vacuum, a channel may be created inthe lid which can be release-ably connected to a traditional rolled lipcoffee cup, among other common liquid holding vessels but be made out ofbiodegradable material.

SUMMARY

By creating a slurry, forming it in a mold under a vacuum, a channel maybe created in the lid which can be release-ably connected to atraditional rolled lip coffee cup, among other common liquid holdingvessels but be made out of biodegradable material. The resulting lid mayhave a combination of desirable qualities. As one example, the lid maybe somewhat springy. It may be elastic enough such that the lid willgive to allow a complementary cup to fit into the channel to create aseal between the cup and the lids. It also will be firm enough towithstand the weight and pressure of the liquid inside the container andfrom pressure from consumers while using the container. The lid also maybe sufficiently heat resistant to withstand desired temperatures andliquid exposure for a time long enough for a consumer to enjoy thecontents of the container but also be biodegradable.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an illustration of a sample lid;

FIG. 2 is an illustration of a method of manufacturing the lid;

FIG. 3 is an illustration of inspecting the lid; and

FIG. 4 is an illustration of the lid.

SPECIFICATION

Herein is provided a material and method for creating a biodegradablelid. The articles and methods described herein may be understood morereadily by reference to the following detailed description and theexamples provided. It is to be understood that this invention is notlimited to the specific components, articles, processes and/orconditions described, as these may, of course, vary. It is also to beunderstood that the terminology used herein is for the purpose ofdescribing particular embodiments only and is not intended to belimiting. Ranges may be expressed herein as from “about” or“approximately” one particular value and/or to “about” or“approximately” another particular value. When such a range isexpressed, another embodiment includes from the one particular valueand/or to the other particular value. Similarly, when values areexpressed as approximations, by use of the antecedent “about,” it willbe understood that the particular value forms another embodiment.

FIG. 1 may illustrate a sample coffee lid 10 that is biodegradable. Lids10 are well known. In general, lids 10 cover or attach to a cup orcontainer. Some lids 10 have opening 20 from which a user can drink.Other lids 10 are solid with no openings 20. Lids 10 are usuallyremove-ably connected to a container.

Certain lids 10 are subject to additional challenges. As an example andnot limitation, lids 10 for coffee must be able to withstand significantheat without immediately degrading or affecting the taste of the coffee.Additionally, consumers are accustomed to coffee lids 10 not changingcolor once the lid 10 has come in contact with coffee. Further, the lid10 has to not stick to the mouth of the consumer, either when warm orwhen cold. At the same time, the lids 10 have to be able to be used forthe delivery and/or storage of beverages for human consumption or forthe delivery of other materials not for human consumption. Examples ofliquids that can be contained include beverages, syrups, concentrates,soaps, inks, gels, solids, chemicals and powders. The vessels orcontainers, for example and not limitation, may be coffee cups, whichmay be made of one type of material, facilitating full recycling of thematerials. In other embodiments, the container can be a combination ofseveral types of materials. There is no requirement that the lid 10 andcontainer be of the same material.

Manufacturing a biodegradable release-ably connectable lid 10 has longbeen a challenge. Forming a channel 40 in a lid 10 using biodegradablematerial which does not unacceptably degrade, deform or discolor when incontact with hot liquid such as coffee has been thought to beimpossible. By creating a slurry, forming it in a mold under a vacuum, achannel 40 may be created in the lid 10 which can be release-ablyconnected to a traditional rolled lip coffee cup, among other commonliquid holding vessels/containers but be made out of biodegradablematerial.

FIG. 2 may illustrate a process of creating a lid 10 that can beremove-ably connected to a container with a rolled lip but still bedegradable. The material used for forming the lids may be food-grade.The material may be biodegradable materials, such as molded fiber orpulp or paper. For example, the lids 10 may be 100% post consumer fiberor pulp feedstock. In another example, the lids 10 may be 100% recycledcorrugated fiberboard and newspaper. The materials described herein caninclude virgin pulp fiber and may include type-2 molded fiber, type-2Athermoformed fiber, type-3 thermoformed fiber, type-4 thermoformedfiber, molded fiber, X-RAY formed fiber, infrared formed fiber,microwave formed fiber, vacuum formed fiber, structural fiber, sheetstock, recycled plastic or any other structural material. Any of thematerials that may be used to form the lid 10 may be used in any of theembodiments described herein.

The lids 10 may include an accelerator that helps promote thedegradation of the lids 10 after use. Alternatively or additionally,additives may be included which help breakdown the intended content ofthe lids 10—for example where the container is to carry oil, an additivemay be included in the lid 10 which helps breakdown oil over time,increasing the recyclable properties of the container.

At block 205, a firm pulp is softened. The firm pulp may be, for exampleand not limitation, sugarcane, rice, bamboo, wood fiber, recycled paperor wheat fibers. Of course, other sources of firm pulp may be possibleand are contemplated.

The softening may entail soaking the firm pulp in a liquid. The liquidmay be, for example and not limitation, water. In some embodiments, thewater is simple potable tap water. In other embodiments, the water isfurther filtered. Additional additives may also be added to the liquidsuch as edible coloring agents. Of course, other liquids may beappropriate and are contemplated. Other softening recipes are possible.

At block 210, food grade water and oil resistants may be added to theslurry. By way of example and not limitation, the food grade water andoil resistants may include DuPont Zonyl 9464. Of course, other waterresistants and oil resistants are possible.

The pulp may be compressed into a pulp pool until the pulp pooltransforms into a slurry. In one embodiment, pressure is applied to thepulp pool using, for example and not limitation, hydraulic pressure. Inanother embodiment, the pressure is applied until a desired liquidcontent is present in the slurry or until the slurry reaches a desiredtemperature. In other embodiments,

At block 215, the slurry may be filtered. The filtering may beaccomplished using any appropriate filtering method or device. As anexample and not limitation, a mesh screen may be used. Of course, otherfiltering methods and apparatus are possible and are contemplated.

At block 220, the slurry may be pumped into a molding device. As isknown, a mold may be used to form a raw material, such as metal, or inthis case, a slurry into a desired shape. The shape may be determined bya pattern. As an example and not limitation, the mold may be made bymaking a pattern using copper and steel with a thickness of 30 mm to 50mm or some other material that cannot be melted away or by a materialthat is hard and does not deflect that is used to create a void that isfilled with the slurry.

At block 225, the slurry may be received in a mesh net over the moldunder vacuum. The mesh net is used to further filter the slurry andremove any large chunks from the slurry. The vacuum is used to pull theraw material, specifically, the slurry, into virtually all the voids ofthe mold. In this case, the mold may define a lid 10 that has a channel40 capable of being snapped over and be remove-ably connected to a cupor other container. FIG. 4 may be an illustration of one possible lid 10and complementary container 70.

The channel 40 may be of a size and shape to snap over the rolled edge60 of a cup 70 or other container. In one embodiment, the channel 40 issubstantially round or annular. In another embodiment, the channel 40 ismore oval in shape. In virtually all embodiments, the shape and size ofthe channel 40 is designed in a way to be remove-ably connectable to acontainer 70. The channel 40 may be complementary to the portion of thelid 10 that will fit into the channel 40. In the coffee cup example, thechannel 40 may be substantial round to match the size and shape of therolled top 60 of a coffee cup or other container 70.

The sides 30 of the lid 10 may be virtually any shape. The sides 30 maybe designed to ease the purpose of the lid 10. For example, if the lid10 is for coffee, the sides 30 may be substantially vertical to easedrink-ability. In another embodiment, the sides 30 may be short in orderto minimize the height of the lid 10 to ensure it stays on and is notbumped off during transport. The sides 30 may be linear or may be curvedbased on purpose and aesthetics. The sides 30 may be substantiallyperpendicular to the top of the lid 10. Of course, other designs for thesides 30 of the lid 10 are possible and are contemplated.

The top of the lid 10 may have a hole or opening 20 to allow the liquidin the container 70 to flow. The hole 20 may be of any useful shape,such as an oval or circle. In some embodiments, the hole 20 may be onthe top of the lid 10 and in other embodiments, the hole may be on aside 30 of the lid 10. In some embodiments, the hole 20 in the lid 10may be re-closeable. As an example and not limitation, the hole 10 maybe a spout that it part of or attached to the lid 10 and the spout maybe sealable. In another embodiment, the lid 10 may have a section thatmay be peeled back to allow drinking but may be peeled forward tovirtually reseal the lid 10. In yet another embodiment, the hole 20 maybe in a depression of the lid 10 to improve drink-ability.

The lids 10 may also have a relief hole 80 as part of the lid 10 toallow liquid to flow in a continuous fashion from the container. Thepurpose of the relief hole 80 is to allow air to fill the space whenliquid leaves the container to allow smooth, uninterrupted pouring fromthe container 70.

The outside edge of the lid may be flared 50 to allow the lid 10 to moreeasily be placed onto the container 70. In some embodiments, the flare50 may be curved and in other embodiments, the flare 50 may be slight.The bottom of the lid 10 may be treated such that the bottom is notsharp enough to cause a cut of human during its foreseeable and intendeduses.

At block 230, the slurry may be dehydrating to form a rough lid 10.Dehydrating may occur in any appropriate manner. In one embodiment, heatis applied to the lid 10 to remove moisture. In another embodiment, airis circulated to assist the removal of moisture. In some embodiments,both circulation of air and heat are used to assist removal of themoisture in the slurry. Of course, the dehydration may be accomplishedby placing the lids 10 in a dry area and allowing the lids to naturallydehydrate. In one example, dehydration is accomplished by subjecting thelids to a temperature of approximately 228 degrees Fahrenheit for asufficient period of time.

At block 235, the finished lid 10 may be created. As the slurry ispoured in the mold, excess slurry may be attached to the lids 10. Theexcess material may be cut from the rough lid 10 so that the lid 10 mayhave no rough edges and a form that will release-ably connect to acontainer 70.

At block 240, the lid 10 may be inspected to determine whether the lidis acceptable. For example and not limitation, the appearance of thefinished lid may be reviewed to determine if it is acceptable. Somepossible checks include determining if the appearance has color, luster,and lack of creases within appropriate tolerances.

FIG. 3 may illustrate some possible steps in the lid inspection process.At block 300, the inspection process may determine if the finished lid10 weight is within weight limits. If the weight is acceptable, the lid10 may be tested further. If the weight of the lid 10 is outside theweight limits, it may be rejected. If a lid 10 is rejected, it may beused as pulp to begin the process again.

At block 305, it may be determined if the cubage of the lid 10 is withincubage limits. Cubage is term that connotes the content or volume of thelid 10. In some embodiments, a statistically significant number of lids10 from a batch are tested as testing every lid may be onerous. If thecubage is outside the cubage limits, the lid 10 may be rejected and maybe used as pulp to begin the process again. If the cubage is withinacceptable limits, the lid 10 may be tested further.

At block 310, it may be determining if the heat proof ability of thelids 10 is within heat limits. In this test, a random sample of lids 10from a particular batch of lids 10 may be tested to determine if thelids 10 are sufficiently heat proof. In one embodiment, the lids 10 aresubjected to heat near the temperature of hot coffee, such asapproximately 228 degrees Fahrenheit. The heat may be appliedindirectly, such as placing the lids 10 in an oven or the lids 10 may beplaced in a liquid that is near the temperature of hot liquid. Theresponse of the lids 10 to the heat may be observed and if the responseis acceptable, the lids may be subjected to further tests. If the lidsresponse to heat is not acceptable, the lids 10 (or the entire batch oflids 10) may be rejected and the lids 10 may be used as pulp for futurelids 10.

At block 320, it may be determining if microorganisms in the lid 10 arewithin microorganism limits. As the process involves sources which mayhave microorganisms, the microorganisms may survive the manufacturingprocess. In one embodiment, the lids 10 may be examined under amicroscope to determine if the microorganisms are at an acceptablelevel. In some embodiments, the determination is automated. In someembodiments, a statistically significant number of lids 10 from a batchare tested as testing every lid may be onerous. If the determination isthat there are too many microorganisms, the lids 10 may be rejected. Ifpossible, the lids 10 may be treated to eliminate the microorganisms. Ifthe determination is that the microorganism level is acceptable, thelids may be deemed acceptable and may be prepared for shipping.

Referring again to FIG. 2, at block 245, the lids 10 may be sterilized.In one embodiment, the lids 10 may be subject to ultraviolet radiationfor sterilization purposes. Of course, other methods of sterilizationare possible and are contemplated. In addition, the lids 10 may besealed into sealable bags to maintain the sterilized nature of the lids.

The result will be a lid 10 that will biodegrade. Biodegradable meansthe lid 10 will be able to decompose naturally. In other words, the lid10 may be made of substances that will decay relatively quickly as aresult of the action of bacteria and break down into elements such ascarbon that are recycled naturally. The resulting lids 10 may be capableof being broken down and naturally absorbed into the ecosystem.Biodegradable materials may degrade into simple stable compounds thatare not harmful to the environment. Unlike traditional lids that maynever biodegrade, the resulting lids 10 will naturally break down overtime.

Aside from the method of manufacturing the lid 10, the lid 10 itselfwill now be described. FIG. 1 may be an illustration of the lid 10. Thelid 10 may have a grooved channel 40 around the perimeter of the lid 10that can remove-ably receive a rolled lip 60 from a container 70 whereinthe container 70 is made from a variety of materials. The lid 10 may beelastic enough to bend to accept the complementary rolled lip of thecontainer 60 and snap around the complementary rolled lip 60 of thecontainer 70 to make a useful seal such that liquids will not leak outin normal usage.

The lids 10 may consist of a pulp that has been manufactured bysoftening a firm pulp by soaking the firm pulp in a liquid until thepulp forms into a pulp pool and then into a slurry. Food grade water andoil resistants may be added to the slurry, the slurry may be filteredand the slurry may be pumped into a molding device. The slurry may bereceived in a mesh net over the mold under vacuum wherein the molddefines a lid 10 that has a grooved channel 40 around the perimeter ofthe lid 10 that can remove-ably receive a rolled lip 60 from a container70 that is capable of being snapped over and be remove-ably connected toa cup 70 to form a releasable seal. The slurry may be dehydrated to forma rough lid 10 and the rough lid 10 may be finished by cutting theexcess material from the rough lid 10. The lid 10 may be inspected tosee if it meets the desired tolerances such as whether the appearance ofthe finished lid 10 is acceptable (color, luster, lack of creases withintolerances), if the finished lid 10 weight is within weight limits, ifthe cubage is within cubage limits, if the heat proof ability is withinheat limits and if microorganisms are within microorganism limits. Thelids 10 may be sterilized by subjecting the lids 10 to ultravioletradiation.

The resulting lid 10 may have a combination of desirable qualities. Asone example, the lid 10 may be somewhat elastic. It may be elasticenough such that the lid 10 will give to allow a complementary cup top60 to fit into the channel 40 to create a seal between the cup top 60and the lids 10. It also may be firm enough to withstand the weight andpressure of the liquid inside the container and from pressure fromconsumers while using the container. The lid 10 also may be sufficientlyheat resistant to withstand desired temperatures and liquid exposure fora time long enough for a consumer to enjoy the contents of the containerbut also be biodegradable.

It should be understood from the foregoing that, while particularimplementations have been illustrated and described, variousmodifications can be made thereto and are contemplated herein. It isalso not intended that the claims be limited by the specific examplesprovided within the specification. Parts of one embodiment may be easilyremoved and added to another embodiment. While the claims have beendescribed with reference to the aforementioned specification, thedescriptions and illustrations of the preferable embodiments herein arenot meant to be construed in a limiting sense. Furthermore, it shall beunderstood that all aspects of the claims are not limited to thespecific depictions, configurations or relative proportions set forthherein which depend upon a variety of conditions and variables.

Various modifications in form and detail of the embodiments of the claimwill be apparent to a person skilled in the art. It is thereforecontemplated that the claim shall also cover any such modifications,variations and equivalents. While preferable embodiments of the claimshave been shown and described herein, it will be obvious to thoseskilled in the art that such embodiments are provided by way of exampleonly. Numerous variations, changes, and substitutions will now occur tothose skilled in the art without departing from the claims. It should beunderstood that various alternatives to the embodiments of the inventiondescribed herein may be employed in practicing the claims.

1. A bio-degradable lid that can be remove-ably connected to a containerwith a rolled lip created by the process comprising: softening a firmpulp comprising soaking the firm pulp in a liquid; allowing the pulp tosoften into a pulp pool until the pulp pool transforms into a slurry;adding food grade water and oil resistants to the slurry; filtering theslurry; pumping the slurry into a molding device; receiving the slurryin a mesh net over the mold under vacuum wherein the mold defines a lidthat has a rolled edge capable of being snapped over and be remove-ablyconnected to a cup; dehydrating the slurry to form a rough lid; creatingthe finished lid comprising cutting the excess material from the roughlid; inspecting the lid comprising: determining if the appearance of thefinished lid is acceptable comprising determining if the appearance hascolor, luster, lack of creases within tolerances; determining if thefinished lid weight is within weight limits; determining if the cubageis within cubage limits; determining if the heat proof ability is withinheat limits; and determining is microorganisms are within microorganismlimits; sterilizing the lids comprising subjecting the lids toultraviolet radiation; wherein the lid will biodegrade.
 2. The lid ofclaim 1, wherein filtering the slurry further comprises using a meshtype filter.
 3. The lid of claim 1, wherein the process furthercomprising sealing the lids into sealable bags.
 4. The lid of claim 1,wherein the process further comprising inspecting the lids against finaltolerances.
 5. The lid of claim 1, wherein the firm pulp is selectedfrom a group comprising: sugarcane, rice, bamboo, wood fiber, recycledpaper and wheat.
 6. The lid of claim 1, wherein the lids furthercomprises a top that comprises a hole to allow liquid to flow and arounded sidewall that is substantially perpendicular to the top, isconnected to the top and is flared to allow the sidewall to be placedover a receiving container.
 7. The lid of claim 6, wherein the groovedchannel is part of the sidewall.
 8. A biodegradable lid for a containerwherein the container is made from a variety of materials, the lidcomprising: a top that comprises a hole for liquid to flow; a roundedsidewall that is substantially perpendicular to the top, connected tothe top and is flared to allow the sidewall to be placed over areceiving container; a grooved channel around the perimeter of the lidthat can remove-ably receive a rolled lip from the receiving containerwherein the receiving container is made from a variety of materials;wherein the lid comprises a pulp that has been manufactured by:softening a firm pulp comprising soaking the firm pulp in a liquid;allowing the pulp to soften into a pulp pool until the pulp pooltransforms into a slurry; adding food grade water and oil resistants tothe slurry; filtering the slurry; pumping the slurry into a moldingdevice; receiving the slurry in a mesh net over the mold under vacuumwherein the mold defines a lid that has a grooved channel around theperimeter of the lid that can remove-ably receive a rolled lip from acontainer that comprises a variety of materials and that is capable ofbeing snapped over and be remove-ably connected to a cup to form areleasable seal; dehydrating the slurry to form a rough lid; creatingthe finished lid comprising cutting the excess material from the roughlid; inspecting the lid comprising: determining if the appearance of thefinished lid is acceptable comprising determining if the appearance hascolor, luster, lack of creases within tolerances; determining if thefinished lid weight is within weight limits; determining if the cubageis within cubage limits; determining if the heat proof ability is withinheat limits; and determining is microorganisms are within microorganismlimits; and sterilizing the lids comprising subjecting the lids toultraviolet radiation and wherein the lid will biodegrade.
 9. The lid ofclaim 8, wherein filtering the slurry further comprises using a meshtype filter.
 10. The lid of claim 8, wherein the process furthercomprising sealing the lids into sealable bags.
 11. The lid of claim 8,wherein the process further comprising inspecting the lids against finaltolerances.
 12. The lid of claim 8, wherein the firm pulp is selectedfrom a group comprising: sugarcane, rice, bamboo, wood fiber, recycledpaper and wheat.
 13. The lid of claim 8, wherein the grooved channel ispart of the sidewall.
 14. A method of manufacturing a biodegradable lidcomprising: softening a firm pulp comprising soaking the firm pulp in aliquid; allowing the pulp to soften into a pulp pool until the pulp pooltransforms into a slurry; adding food grade water and oil resistants tothe slurry; filtering the slurry; pumping the slurry into a moldingdevice; receiving the slurry in a mesh net over the mold under vacuumwherein the mold defines a lid that has a rolled edge capable of beingsnapped over and be remove-ably connected to a cup; dehydrating theslurry to form a rough lid; creating the finished lid comprising cuttingthe excess material from the rough lid; inspecting the lid comprisingdetermining if the appearance of the finished lid is acceptable; andsterilizing the lids comprising subjecting the lids to ultravioletradiation.
 15. The method of claim 14, wherein determining if theappearance of the finished lid is acceptable further comprises:determining if the appearance has color, luster, lack of creases withintolerances; determining if the finished lid weight is within weightlimits; determining if the cubage is within cubage limits; determiningif the heat proof ability is within heat limits; and determining ismicroorganisms are within microorganism limits.
 16. The method of claim14, further comprising sealing the lids into sealable bags.
 17. Themethod of claim 14, further comprising inspecting the lids against finaltolerances.
 18. The method of claim 14, wherein the firm pulp isselected from a group comprising: sugarcane, rice, bamboo, wood fiber,recycled paper and wheat.
 19. The method of claim 14, wherein the lidfurther comprises a top that comprises a hole to allow liquid to flowand a rounded sidewall that is substantially perpendicular to the top,is connected to the top and is flared to allow the sidewall to be placedover a receiving container.
 20. The method of claim 19, wherein thegrooved channel is part of the sidewall.